A61F2/86—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure

A61F2/90—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure

A61F2/91—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes

A61F2/915—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes with bands having a meander structure, adjacent bands being connected to each other

A61F2/86—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure

A61F2/90—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure

A61F2/91—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes

A61F2/86—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure

A61F2/90—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure

A61F2/91—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes

A61F2/915—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes with bands having a meander structure, adjacent bands being connected to each other

A61F2002/91525—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes with bands having a meander structure, adjacent bands being connected to each other within the whole structure different bands showing different meander characteristics, e.g. frequency or amplitude

A61F2/86—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure

A61F2/90—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure

A61F2/91—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes

A61F2/915—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes with bands having a meander structure, adjacent bands being connected to each other

A61F2002/9155—Adjacent bands being connected to each other

A61F2002/91575—Adjacent bands being connected to each other connected peak to trough

Abstract

Described herein are implantable medical devices for delivering a therapeutic agent to the body tissue of a patient, and methods for making such medical devices. In particular, the implantable medical devices, such as intravascular stents, have a coating which includes at least one coating composition and has an exposed abluminal surface and an exposed luminal surface or exposed side surface.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims benefit under 35 USC 120 to, international application PCT/US2008/008900, filed Jul. 22, 2008, which claims benefit of U.S. Ser. No. 60/953,736, filed Aug. 3, 2007. International application PCT/US2008/008900 is hereby incorporated by reference in its entirety.

INTRODUCTION

Described herein are implantable medical devices for delivering a therapeutic, agent to the body tissue of a patient, and methods for making such medical devices. In particular, certain embodiments are directed to implantable medical devices, such as intravascular stents, having a coating with increased surface area, wherein the coating includes at least one coating composition that has an exposed abluminal surface and an exposed luminal surface or an exposed side surface.

BACKGROUND

Medical devices comprising a therapeutic agent have been successful in treating the body tissue of a patient. For example, intravascular stents that have a coating containing, a therapeutic agent for preventing restenosis have been successful in reducing incidents of restenosis. In certain instances, in order to improve the reduction of restenosis, it may be desirable to increase the amount of the therapeutic agent that is delivered from the coating to the body tissue.

One way of increasing the amount of therapeutic agent that is delivered to the body tissue is to increase the amount of the therapeutic agent that is loaded into the coating. However, there are difficulties associated with coatings that contain large amounts of a therapeutic agent, such as controlling the release of the therapeutic agent. Particularly, larger amounts of therapeutic agents in the coating can be released too rapidly from the coating, thereby creating a “burst” effect instead of a desired sustained release of the therapeutic agent.

Another way of increasing the amount of therapeutic agent that is included in a medical device coating and delivered to the body tissue is to increase the surface area of the coating that is exposed to the tissue. In general, when a coating composition is disposed on the surface of a medical device, such as a stent, the exposed surface area of the coating is generally equivalent to the surface area of the medical device upon which the coating is disposed. Thus, the surface area of the medical device surface limits the exposed surface area of the coating.

One way to increase the exposed surface area of the coating is to remove material from the surface of the medical device to increase the surface area upon which a coating can be disposed. However, removing material from the medical device can adversely impact the structural integrity of the medical device. For example, if holes are created in the struts of a stent, the structural integrity of the stent struts can be compromised causing the struts to become weak. Weak struts could result in the stent failing to expand properly or, once implanted, collapsing, potentially causing re-occlusion of a body lumen.

Accordingly, there is a need for a medical device having a coating with an increased exposed surface area for delivering a therapeutic agent to body tissue. Furthermore, there is a need for methods of making such medical device coatings having increased exposed surface area that do not adversely affect the structural integrity of the medical device

SUMMARY

These and other objectives are addressed by the coatings and medical devices described herein. Described herein are medical devices, such as intravascular stents, that comprise a coating having an increased exposed surface area for delivering a therapeutic agent to a patient. The increased exposed surface area of the coating allows a greater amount of a therapeutic agent to be delivered from the coating in a controlled release manner, thereby avoiding any undesirable early or rapid release of the therapeutic agent. Moreover, the coatings described herein are capable of accomplishing the above objectives without compromising the structural integrity of the medical device.

Certain embodiments include an implantable stent having a stent sidewall structure having an abluminal surface and a luminal surface opposite the abluminal surface and a coating comprising a coating composition disposed on at least a portion of the abluminal surface. The coating has an exposed abluminal surface and an exposed luminal surface or an exposed side surface. An exposed surface is a surface that is not covered by another material.

Some embodiments include an implantable intravascular stent having a stent sidewall structure comprising a plurality of struts and a plurality of openings in the stent sidewall structure. At least one strut has an abluminal surface and a luminal surface opposite the abluminal surface. A coating comprising a coating composition is disposed directly on at least a portion of the abluminal surface of a strut such that the coating has an exposed abluminal surface and an exposed luminal surface or an exposed side surface. The coating composition comprises a biostable polymer and an anti-restenosis agent.

Other embodiments include an implantable stent having a stent sidewall structure having an abluminal surface and a luminal surface opposite the abluminal surface and a coating disposed on at least a portion of the abluminal surface. The coating includes a first coating composition disposed on at least a portion of the abluminal surface and a second coating composition disposed on the first coating composition. The coating has an exposed abluminal surface and an exposed luminal surface or an exposed side surface.

Still other embodiments include an implantable intravascular stent having a stent sidewall structure comprising a plurality of struts and a plurality of openings in the stent sidewall structure. At least one strut has an abluminal surface and a luminal surface opposite the abluminal surface. A coating is disposed on at least a portion of the abluminal surface of a strut. The coating includes a first coating composition disposed directly on at least a portion of the abluminal surface of the strut, wherein the first coating composition comprises a first biostable polymer, and a second coating composition disposed directly on the first coating composition. The second coating composition includes a second biostable polymer and an anti-restenosis agent. The coating has an exposed abluminal surface and an exposed luminal surface or an exposed side surface.

Other embodiments described herein include an implantable stent having a stent sidewall structure having an abluminal surface and a luminal surface opposite the abluminal surface and a coating disposed on at least a portion of the abluminal surface. The coating includes a first coating composition disposed on at least a portion of the abluminal surface, a second coating composition disposed on the first coating composition and a third coating composition disposed on the second coating composition. The coating has an exposed abluminal surface and an exposed luminal surface or an exposed side surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of a stent that is suitable for use in the embodiments described herein.

FIGS. 2A-2F show cross-sectional views of embodiments where a portion of a stent strut has a coating composition disposed thereon.

FIGS. 3A-3E show cross-sectional views of embodiments where a portion of a stent strut has two coating compositions disposed thereon.

FIG. 4A-4C show cross-sectional views of embodiments where a portion of a stent strut has three coating compositions disposed thereon.

FIG. 5 shows a perspective view of a portion of a stent strut having a coating that extends along a portion of the strut.

FIG. 6 shows a perspective view of another stent strut having a coating disposed on portions of the surface of the stent strut.

FIG. 7 shows a perspective view of a stent having a coating that forms a mirror-image of the portion of abluminal surface of the stent upon which the coating is disposed.

FIGS. 8A-8H show cross-sectional views of additional embodiments where a portion of a stent strut has a coating composition disposed thereon.

FIG. 9A-9B show a method for making a coated medical device in accordance with the methods described herein.

FIG. 10A-10C show another method for making a coated medical device in accordance with the methods described herein.

FIG. 11A-11D show yet another method for making a coated medical device in accordance with the methods described herein.

FIG. 12A-12D show still another method for making a coated medical device in accordance with the methods described herein.

FIG. 13A-13E show another method for making a coated medical device in accordance with the methods described herein.

FIG. 14A-14C show yet another method for making a coated medical device in accordance with the methods described herein.

DETAILED DESCRIPTION

The coatings of the embodiments described herein can be used in connection with any medical device that has a surface. FIG. 1 shows an example of a medical device that is suitable for use in the embodiments described herein. This figure shows an implantable intravascular stent 10 comprising a sidewall 20 which has a first sidewall surface 22 and an opposing second sidewall surface, which is not shown in FIG. 1. The first sidewall surface 22 can be an outer or abluminal sidewall surface, which faces the body lumen wall when the stent is implanted, or an inner or luminal sidewall surface, which faces away from the body lumen wall and towards the center of the lumen. Stent 10 also has a plurality of struts 30 and at least one opening 40 in the sidewall 20. Generally, the opening 40 is disposed between adjacent struts 30. Suitable stent sidewall structures have a plurality of struts and openings and wherein at least one strut comprises an abluminal surface, which forms part of the abluminal surface of the stent upon which the coating composition is disposed, and the strut comprises a luminal surface opposite the abluminal surface of the strut, which forms part of the luminal surface of the stent. In a stent having an opening in the stent sidewall structure, in certain embodiments, it is preferable that the coating applied to the stent conforms to the surface of the stent so that the openings in the sidewall stent structure are preserved, e.g. the openings are not entirely or partially occluded with coating material.

FIG. 2 A shows a cross-sectional view of an embodiment where a portion of a stent strut 50 has a coating 60 comprising a coating composition 62 disposed thereon. The stent strut 50 has an abluminal surface 52 and a luminal surface 54. In this embodiment, a coating 60 is disposed on the abluminal surface 52 of stent strut 50. The coating includes a coating composition 62 comprising a coating material 64, such as a polymer, metal, metal oxide, ceramic oxide, inert carbon or combination thereof, and a therapeutic agent 66. Also, the coating material 64 can be the same or different from the material that forms the strut 50. The coating composition 62 has an exposed abluminal surface 68, which faces the luminal wall, an exposed luminal surface 69, which faces the center of the lumen and exposed side surfaces 65.

Unlike coatings that only have an exposed abluminal surface, e.g. the surface of the coating that faces the body lumen, from which the therapeutic agent can be released, the coatings described herein also include an exposed luminal surface 69, e.g. the surface of the coating that faces the center of the lumen, from which the therapeutic agent 66 can be released, or exposed side surfaces 65, e.g. surfaces that are perpendicular to or at an angle with an abluminal or luminal surface. The embodiment of the coating shown in FIG. 2 A has an exposed abluminal surface 68, an exposed luminal surface 69 and two exposed side surfaces 65. Therefore, in the embodiment shown in FIG. 2A, a therapeutic agent can be released from surfaces 68 and 69, as well as, surfaces 65. The increased surface area from which the therapeutic agent can be released allows more of the therapeutic agent in the coating to be released and less of the therapeutic agent to remain unused in the coating.

As shown in FIG. 2 A, the luminal surface 54 of the strut, which is the surface that faces the center of the body lumen and faces away from the body lumen wall, is substantially free of the coating 60. As used herein the phrase, “substantially free of the coating” means that the coating is not intentionally disposed on the surface. In alternative embodiments, a coating can be disposed on the luminal surface as well as the abluminal surface. The coating disposed on the luminal surface can be the same or different from the coating disposed on the abluminal surface. For example, the coating disposed on the abluminal surface can include a coating composition comprising a therapeutic agent that can be exposed or introduced to a blood vessel wall. The coating disposed on the luminal surface can include a coating composition comprising a therapeutic agent or surface that can be exposed or introduced to the bloodstream. In another embodiment, the coating disposed on the luminal surface can include a coating composition without a therapeutic agent. In other embodiments, a coating can be disposed on the luminal surface while the abluminal surface is substantially free of any coating.

FIG. 2B shows another embodiment of a coating 60 comprising a coating composition 62 having an exposed abluminal surface 68, an exposed luminal surface 69 and two exposed side surfaces 65. Coating 60 also includes a coating composition 64 and a therapeutic agent 66. Unlike the embodiment shown in FIG. 2A, in this embodiment the strut 50 comprises a portion 58 that extends past its abluminal surface 52. The coating composition 62 is disposed on the extended portion 58.

The embodiments shown in FIGS. 2C and 2D are respectively similar to those shown in FIGS. 2A and 2B. However, in the coatings 60 shown in FIGS. 2C and 2D, the therapeutic agent 66 is not dispersed throughout the coating composition 62. Instead, the therapeutic agent 66 is disposed at or near the exposed abluminal surface 68, exposed luminal surface 69 and exposed side surfaces 65 of the coating composition 62.

In the embodiments shown in FIGS. 2A-2D, the coating composition 62 is disposed directly on, i.e. in physical contact with a strut surface. FIGS. 2E and 2F show two embodiments where the coating composition 62 is not disposed directly on the surface 52 of the strut 50. Instead, an intervening material 56, such as an adhesive or other material that enhances the adhesion of the coating composition to the strut surface, is disposed between the coating composition 62 and the strut surface 52.

FIGS. 3A-3E show cross-sectional views of embodiments where coatings comprising first and second coating compositions are disposed on a stent strut surface. In FIG. 3 A, the coating 160 comprises a first coating composition 170 disposed on at least a portion of the abluminal surface 152 of a stent strut 150. A second coating composition 162 is disposed on the first coating composition 170. The second coating composition 162 has an exposed abluminal surface 168, an exposed luminal surface 169 and exposed side surfaces 165. The first coating composition 170 comprises a first coating material 172, such as a polymer, metal, metal oxide, ceramic oxide, inert carbon or combination thereof. The second coating composition 162 comprises a second coating material 164, such as a polymer, metal, metal oxide, ceramic oxide, inert carbon or combination thereof. The first coating composition 170 can be the same or different as the second coating composition 162. Moreover, the first or second coating materials 172, 164 can be the same or different from the material that forms the strut 150. As shown in FIG. 3A, the second coating composition 162 also includes a therapeutic agent 166. In certain embodiments, the first coating composition 170 can also include a therapeutic agent that is the same as or different from the therapeutic agent 166 of the second coating composition 162.

In certain embodiments, the first coating composition has a first exposed abluminal surface area when disposed on the abluminal surface, prior to the deposition of the second coating composition, and the second coating composition comprises a second exposed abluminal surface area when disposed on the first coating composition, wherein the second exposed abluminal surface area is greater than the first exposed abluminal surface area.

FIG. 3B shows another embodiment that is similar to that shown in FIG. 2B except that the coating 160 comprises a first and second coating composition 170, 162. In particular, in FIG. 3 B, the coating 160 comprises a first coating composition 170 that is disposed on a portion 158 of the stent strut 150 that extends past its abluminal surface 152. A second coating composition 162 is disposed on the first coating composition 170 and the second coating composition 162 has an exposed abluminal 168, an exposed luminal surface 169 and exposed side surfaces 165.

The embodiment shown in FIG. 3C is similar to that shown in FIG. 3A. However, in the coating 160 shown in FIG. 3C, the therapeutic agent 166 is not dispersed throughout the second coating composition 162. Instead, the therapeutic agent 166 is disposed at or near the exposed abluminal 168, exposed luminal 169 and exposed side surfaces 165 of the second coating composition 162.

FIG. 3D shows an embodiment with a coating 160 comprising a first and second coating composition 170, 162 where the first coating composition 170 has an abluminal surface 174 and luminal surface 176 as well as two side surfaces 178. The second coating composition 162 is disposed on the abluminal surface 174, luminal surface 176 and two side surfaces 178 of the first coating composition 170. The second coating composition has an exposed abluminal surface 168, an exposed luminal surface 169 and exposed side surfaces 165.

FIGS. 3A-3D show the first coating composition 170 disposed directly on the abluminal 152 surface of the stent strut 150 and the second coating composition 162 disposed directly on the first coating composition 170; however, in other embodiments, an intervening material can be disposed between the first coating composition 162 and the abluminal surface 152 of the strut 150, such that the first coating composition would not be disposed directly on the abluminal surface of the stent. Alternatively, an intervening material can be disposed between the first coating composition 162 and the second coating composition 170, such that the first coating composition would not be disposed directly on the second coating composition. FIG. 3E shows a coating 160 comprising a first and second coating composition 170, 162 with an intervening material 156, such as an adhesive agent, shown in FIGS. 2E and 2F, disposed between the two coating compositions.

The coating disposed on the abluminal surface of a medical device can also include a first coating composition disposed on at least a portion of the surface of a medical device, a second coating composition disposed on the first coating composition and a third coating composition containing a therapeutic agent disposed on the exposed surfaces of the second coating composition, wherein the third coating composition has an exposed abluminal surface and an exposed luminal surface, as shown in FIGS. 4A-4C.

FIG. 4A shows a stent strut 250 having an abluminal surface 252, a luminal surface 254, and a coating 260. The coating 260 comprises a first coating composition 280 disposed on at least a portion of the abluminal surface 252 of a stent strut 250. A second coating composition 270 is disposed on the first coating composition 280 and a third coating composition 262 is disposed on the second coating composition 270. The third coating composition 262 has an exposed abluminal surface 268, an exposed luminal surface 269 and exposed side surfaces 265. The first coating composition 280 includes a first coating material 282, such as a polymer, metal, metal oxide, ceramic oxide, inert carbon or combination thereof. The second coating composition 270 comprises a second coating material 272, such as a polymer, metal, metal oxide, ceramic oxide, inert carbon or combination thereof. The third coating composition 262 comprises a third coating material 264, such as a polymer, metal, metal oxide, ceramic oxide, inert carbon or combination thereof. The first, second or third coating compositions 280, 270, 262 can include the same or different materials. Moreover, the first, second or third coating materials 282, 272, 264 can be the same or different from the material that forms the strut 250. As shown in FIG. 4A, the third coating composition 262 also includes a therapeutic agent 266. In certain embodiments, the first or second coating composition 280 and 270 can also include a therapeutic agent that is the same or different from the therapeutic agent 266 of the third coating composition 262.

FIG. 4B shows a coating that includes three coating compositions. The coating 260 includes a first coating composition 280 directly disposed on a portion 258 of the stent strut 250 that extends past its abluminal surface 252. A second coating composition 270 is disposed on the first coating composition 280 and a third coating composition 262 is disposed on the second coating composition 270. The third coating composition 262 has an exposed abluminal 268, an exposed luminal surface 269 and exposed side surfaces 265, as well as a therapeutic agent 266 disposed therein.

FIGS. 4A and 4B show the third coating composition disposed directly on the second coating composition and the second coating composition disposed directly on the first coating composition, however, the third and second coating compositions do not have to be disposed directly on the second and first coating compositions. FIG. 4C shows a coating 260 comprising a first, second and third coating composition 280, 270, 262 with an intervening material 256 disposed between the first and second coating compositions 280 and 270. In other embodiments, an intervening material can be disposed between the first coating composition 280 and the abluminal surface 252 of the strut 250.

Compared to the embodiments shown in FIGS. 2A-2F, 3A-3E and 4A-4C which are cross-sectional views, FIG. 5 shows a perspective view of a coating similar to that of FIG. 2A in which the coating 60 extends along the length of the strut 50. The strut 50 has an abluminal surface 52 and a luminal surface 54. Coating 60 is disposed on the abluminal surface 52 of the strut. Coatings such as those shown in the above-described figures can also be disposed on a strut in this configuration. The coating 60 comprises a coating composition 62 that has an exposed abluminal 68, an exposed luminal surface 69, and exposed side surfaces 65, as well as a therapeutic agent 66.

FIG. 6 shows a perspective view of another embodiment in which a coating 360 includes a coating composition 362 disposed on certain portions of the abluminal surface 352 of the stent strut 350. The coating 360 has an exposed abluminal 368, an exposed luminal surface 369 and exposed side surfaces 365. The coating composition 362 includes a coating material 364 and a therapeutic agent 366. Although the coating composition, disposed on the portions of the stent struts is the same in this figure such coating compositions can be different. Also, additional coating compositions can be disposed on the luminal surface of the stent strut.

In some embodiments, the coating disposed on a portion of the stent surface can be a mirror-image of the portion of the stent surface. For example, FIG. 7 shows a perspective view of a portion of a stent 410 in which a coating 460 is disposed on a portion of the abluminal surface 452 of the stent. The coating 460 includes a coating composition 462 that includes a coating material 464 and a therapeutic agent 466. The coating composition 462 has an exposed abluminal surface 468, an exposed luminal surface 469 and an exposed side surface 467. The abluminal and luminal surface 468 and 469 of the coating composition are mirror-images of the portion of the abluminal surface 452 upon which the coating 460 is disposed. The coating can be prefabricated in the form of a mirror-image of the surface before being disposed on the surface.

In certain embodiments, the coatings can have a cross-section in the shape of a “T” as shown in FIG. 2 or an inverted “T” as shown in FIG. 8A. FIG. 8A shows a coating 500 that has exposed abluminal surfaces 502 and exposed side surfaces 504. In other embodiments, the cross-section of the coating can be in the shape of a modified “T”. For instance, as shown in FIG. 8B, the cross-section of the coating 510 can have an exposed abluminal surface 512, exposed luminal surface 513 and exposed side surfaces 514 with rounded edges 516 and curved surfaces 517. In the embodiment shown in FIG. 8C, the coating 520 has a cross-section in the shape of another modified “T” in which the exposed abluminal surface 522, exposed luminal surface 524 and exposed side surfaces 526 of the “T” have ridges 528. The ridges further increase the exposed surface area of the coating.

In still other embodiments, the cross-section of the coating can be in the form of other shapes. Other suitable shapes are shown in FIG. 8D through FIG. 8H. FIG. 8D shows the cross-section of a coating 530 in the shape of an “I” with an exposed abluminal surface 532, an exposed luminal surface 534 and exposed side surfaces 536. FIG. 8E shows the cross-section of a coating 540 having a “V” shape. The coating has exposed abluminal surfaces 542 and exposed luminal surface 544. FIG. 8F shows the cross-section of a coating 550, which is shaped like an “E”, rotated 90°, with exposed abluminal surfaces 552 and exposed side surfaces 554. FIG. 8G shows the cross-section of a coating 560, which is shaped like a “U”, with exposed abluminal surfaces 562 and exposed side surfaces 564. FIG. 8H shows the triangular cross-section of a coating 570 with an exposed abluminal surface 572 and exposed luminal surfaces 564.

The coatings may be of any thickness. In some embodiments, the coating can have a thickness of about 5 microns to about 40 microns. Preferably the coatings have a thickness of about 5 microns to about 15 microns. In some instances, a relatively thicker coating may be preferred to incorporate greater amounts of a therapeutic agent. Coatings of the embodiments described herein may include multiple layers of coating compositions. For example, coatings can include multiple layers of different coating compositions or multiple layers of the same coating composition.

The coating compositions described herein may also include a plurality of pores. The pores can extend from the surface of a coating composition to the surface of another coating composition or the surface of the medical device. The pores can be any shape including but not limited to, channels, void pathways or microscopic conduits, spheres or hemispheres. Additionally, the pores can have any size or range of sizes. In some instances, the pores can be micropores or nanopores. The pores can also be distributed throughout the coating composition or located in specific areas of the coating composition, such as near the exposed surfaces of the coating compositions. In certain embodiments the pores are located near the exposed abluminal and the exposed luminal surface of a coating composition. Also, pores can be distributed randomly or in a pattern. In certain embodiments, wherein the coating composition also includes at least one therapeutic agent, the therapeutic agent can be disposed in at least some or all of the pores.

A. Medical Devices

Medical devices which are suitable for the embodiments described herein include any stent for medical purposes, which are known to the skilled artisan. Suitable stents include, for example, vascular stents such as self-expanding stents and balloon expandable stents. Examples of self-expanding stents are illustrated in U.S. Pat. Nos. 4,655,771 and 4,954,126 issued to Wallsten and U.S. Pat. No. 5,061,275 issued to Wallsten et al. Examples of appropriate balloon-expandable stents are shown in U.S. Pat. No. 5,449,373 issued to Pinchasik et al. In preferred embodiments, a suitable stent is an Express stent. More preferably, the Express stent is an Express™ stent or an Express2™ stent (Boston Scientific, Inc. Natick, Mass.).

The framework of the suitable stents may be formed through various methods as known in the art. The framework may be welded, molded, laser cut, electro-formed, or consist of filaments or fibers which are wound or braided together in order to form a continuous structure.

Medical devices that are suitable for the embodiments described herein may be fabricated from metallic, ceramic, polymeric or composite materials or a combination thereof. In some instances, the medical device can be made of a non-polymeric material. Preferably, the materials are biocompatible. Metallic material is more preferable. Suitable metallic materials include metals and alloys based on titanium (such as nitinol, nickel titanium alloys, thermo-memory alloy materials); stainless steel; tantalum, nickel-chrome; or certain cobalt alloys including cobalt-chromium-nickel alloys such as Elgiloy® and Phynox®; PERSS (Platinum EnRiched Stainless Steel) and Niobium. Metallic materials also include clad composite filaments, such as those disclosed in WO 94/16646.

Suitable ceramic materials include, but are not limited to, oxides, carbides, or nitrides of the transition elements such as titanium, hathium, iridium, chromium, aluminum, and zirconium. Silicon based materials, such as silica, may also be used.

The coating compositions of described herein can comprise of any coating material such as, but not limited to, polymers, metal oxides, ceramic oxides, metals, inert carbon or combinations thereof. Additionally, the coating compositions can be radiopaque and/or have MRI compatibility. As discussed above the coating compositions described herein can be comprised of the same material or materials or different material or materials.

In alternative embodiments, hydrophilic polymers can be used. Examples of suitable hydrophilic polymers or monomers include, but not limited to; (meth)acrylic acid, or alkaline metal or ammonium salts thereof; (meth)acrylamide; methylenebisacrylamide; (meth)acrylonitrile; polylactic acid; polyglycolic acid; polylactic-glycolic acid; those polymers to which unsaturated dibasic, such as maleic acid and fumaric acid or half esters of these unsaturated dibasic acids, or alkaline metal or ammonium salts of these dibasic adds or half esters, is added; those polymers to which unsaturated sulfonic, such as 2-acrylamido-2-methylpropanesulfonic, 2-(meth)acryloylethanesulfonic acid, or alkaline metal or ammonium salts thereof, is added; and 2-hydroxyethyl(meth)acrylate and 2-hydroxypropyl(meth)acrylate.

Polyvinyl alcohol is also an example of hydrophilic polymer. Polyvinyl alcohol may contain a plurality of hydrophilic groups such as hydroxyl, amido, carboxyl, amino, ammonium or sulfonyl (—SO3). Hydrophilic polymers also include, but are not limited to, starch, polysaccharides and related cellulosic polymers; polyalkylene glycols and oxides such as the polyethylene oxides; polymerized ethylenically unsaturated carboxylic acids such as acrylic, mathacrylic and maleic acids and partial esters derived from these acids and polyhydric alcohols such as the alkylene glycols; homopolymers and copolymers derived from acrylamide; and homopolymers and copolymers of vinylpyrrolidone.

In other embodiments, the coating composition can include inert carbon. Suitable forms of inert carbon can include with out limitation, pyrolitic carbon and porous vitreous carbon. Use of porous carbon can help prevent thrombosis and encourage endothelial cell growth.

The coating materials can comprise at least 5%, at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, at least 97%, at least 99% or more by weight of the coating composition. In certain embodiments where a coating composition includes a polymer, the polymer is about 60% to about 99% by weight of the coating composition. In certain embodiments, where a coating composition includes a metal oxide or ceramic oxide, the metal oxide or ceramic oxide is about 0.1% to about 5% by weight of the coating composition. In certain embodiments, where a coating composition includes a metal, the metal is about 0.1% to about 20% by weight of the coating composition. In certain embodiments, where a coating composition includes carbon, the carbon is about 0.1% to about 50% by weight of the coating composition.

In certain embodiments, the coating composition that has an exposed abluminal surface is free of polymer or substantially free of a polymer. Used herein substantially free of polymer means that any polymer included in the first coating composition is less than 50% by weight of the first coating composition. In such embodiments, the coating compositions can include any of the metal oxides, ceramic oxides, metals or carbons discussed above.

Intervening Materials

Additionally, certain embodiments of the coatings described herein include an intervening material. Suitable intervening materials enhance the adhesion of the coating compositions to other coating compositions or to the surface of the medical device. Intervening materials include, but are not limited to, adhesive materials or textured materials. Suitable adhesive materials include, but are not limited to, parylene C. Suitable textured materials are materials that have a texture that improves the adhesion of the coating composition and can comprise iridium oxides, zirconium oxides, platinum oxides, titanium oxides, tantalum oxides, zinc oxides, iron oxides, magnesium oxides, aluminum oxides, niobium oxides, tungsten oxides, rhodium oxides, ruthenium oxides, silicon oxides or a combination thereof. Textures can be formed by any methods known in the art including, but not limited to laser pitting, micro blasting, sputter coating a thin film, physical vapor deposition, chemical etching, and standard lithographic techniques, such as micro contact printing and photolithography.

C. Therapeutic Agents

The term “therapeutic agent” as used herein encompasses drugs, genetic materials, and biological materials and can be used interchangeably with “biologically active material.” The term “genetic materials” means DNA or RNA, including, without limitation, DNA/RNA encoding a useful protein stated below, intended to be inserted into a human body including viral vectors and non-viral vectors.

The therapeutic agents can be synthesized by methods well known to one skilled in the art. Alternatively, the therapeutic agents can be purchased from chemical and pharmaceutical companies.

In some embodiments, the therapeutic agent comprises at least 1%, at least 5%, at least 10%, at least 15%, at least 20%, at least 30%, at least 40% or more by weight of the coating composition. Weights less than 15% generally allow the agent to elute into the body by diffusion through the polymer matrix. Weights between 15-20% result in faster diffusion, as the agent is allowed to diffuse through voids left by previously-eluted agent. Preferably, the therapeutic agent is between 1% and 30% by weight of the coating composition. In certain embodiments, the therapeutic agent is about 15% by weight of the coating composition.

D. Methods of Making Coatings

Also described herein are methods of making a coated medical device. Methods discussed herein include the steps of disposing a coating composition on at least a portion of the surface of a medical device such that the coating composition has an exposed abluminal surface and an exposed luminal surface or an exposed side surface.

In certain embodiments, the coated medical devices can be made by disposing a coating composition on at least a portion of the surface of a medical device and removing a portion of the coating composition, so that the coating composition has an exposed abluminal surface and an exposed luminal surface.

FIG. 9A shows one embodiment of a method of making a coated medical device. As shown in FIG. 9A, a coating composition 600 is disposed directly on a portion of a surface 610 of medical device 612. Then a portion of the coating composition is removed, as shown in FIG. 9B, so that the coating composition 600 disposed on the surface 610 of a medical device 612 has an exposed abluminal surface 620, an exposed luminal surface 622 and exposed side surfaces 624.

The coatings described herein can also be made by disposing a secondary material or masking material on at least a portion of the surface of a medical device, such as an intervascular stent. A coating composition is then disposed on at least a portion of the surface of a medical device and on a portion of the secondary material or masking material. The secondary material or masking material is removed such that the coating composition has an exposed abluminal surface, an exposed luminal surface and exposed side surfaces. Such a method is shown in FIGS. 10A through 10C. FIG. 10A shows a secondary material or masking material 730 disposed on a portion of the surface 710 of the medical device 712. A coating composition 700 is then disposed on the medical device 712, as shown in FIG. 10B. Once the coating composition 700 is disposed on the medical device 712, the secondary material or masking material 730 can be removed, such that the coating composition 700 has an exposed abluminal surface 720, an exposed luminal surface 722 and exposed side surfaces 724, as shown in FIG. 10C. In certain methods, the secondary material can be mixed with the coating composition wherein the coating composition and the secondary material can be disposed on the surface of the medical device simultaneously.

The above methods can further include the steps of disposing an intervening material on at least a portion of the surface of the medical device. The intervening material can be disposed on the surface of the medical device after the secondary material or masking material has been disposed on at least a portion of the surface of the medical device. The coating composition can then be disposed on at least a portion of the intervening material and the secondary material or masking material. Then the secondary material or masking material can be removed.

The methods of coating a medical device, preferably, an implantable stent, described herein include the steps of disposing a first coating composition on at least a portion of the abluminal surface; and disposing a second coating composition on the first coating composition such that the second coating composition has an exposed abluminal surface and an exposed luminal surface or exposed side surfaces.

In certain embodiments, the methods of coating an implantable stent described herein include the steps of disposing a first coating composition on at least a portion of the abluminal surface; removing at least a portion of the first coating composition; disposing a second coating composition on the first coating composition; and removing at least a portion of the second coating composition such that the second coating composition has an exposed abluminal surface and an exposed luminal surface, as shown in FIGS. 11A through 11D.

As shown in FIG. 11A, a first coating composition 800 is disposed on a portion of a surface 810 of medical device 812. A portion of the first coating composition 800 is then removed as shown in FIG. 11B. Once at least a portion of the first coating composition 800 has been removed from at least a portion of the surface 810 of the medical device 812, a second coating composition 820 is disposed on the first coating composition 800 as shown in FIG. 11C. Once the second coating composition 820 is disposed on the first coating composition 800, if necessary, a portion of the second coating composition 820 is removed so that the second coating composition 820 has an exposed abluminal surface 822, an exposed luminal surface 824 and exposed side surfaces 826, as shown in FIG. 11D.

Another embodiment of the methods described herein is shown in FIGS. 12A-12D, which includes the steps of disposing a secondary material or masking material 900 on a portion of the abluminal surface 910 of a medical device 920, as shown in FIG. 12A. This embodiment is similar to the described in connection with FIGS. 10A-10C. However, this embodiment involves two coating compositions. A first coating composition 930 can be disposed on at least a portion of the abluminal surface 910 of the medical device 920, as shown in FIG. 12B, between the secondary material 900. A second coating composition 940 can then be disposed on at least a portion of the first coating composition 930 and at least a portion of the secondary material or masking material 900, as shown in FIG. 12C. The secondary material or masking material 900 can be removed such that the second coating composition 940 has an exposed abluminal surface 950, an exposed luminal surface 960 and exposed side surfaces 970, as shown in FIG. 12D.

The above methods can further include the step of disposing an intervening material on the first coating composition prior to disposing the second coating composition on the first coating composition. Alternatively, the above methods can further include the step of disposing an intervening material on the surface of the medical device prior to disposing the first coating composition on the medical device, such that the intervening material is between the surface of the medical device and the first coating composition.

The methods of coating a medical device, preferably, an implantable stent, described herein also include the steps of disposing a first coating composition on at least a portion of the abluminal surface; disposing a second coating composition on the first coating composition; and disposing a third coating composition on the second coating composition such that the third coating composition has an exposed abluminal surface and an exposed luminal surface or an exposed side surface. FIGS. 13A-13E show such an embodiment. This method includes the step of disposing a first coating composition 1000 on at least a portion of the abluminal surface 1010 of a stent strut 1020, as shown in FIG. 13A. At least a portion of the first coating composition 1000 can be removed, as shown in FIG. 13B. A second coating composition 1030 can then be disposed on the first coating composition 1000, as shown in FIG. 13C. At least a portion of the second coating composition 1030 can be removed, as shown in FIG. 13D and then a third coating composition 1040 can be disposed on the second coating composition 1030 such that the third coating composition 1040 has an exposed abluminal surface 1050, an exposed luminal surface 1060 and exposed side surfaces 1070, as shown in FIG. 13E. Embodiments of coatings made from such methods are shown in FIG. 4A.

In certain embodiments, methods of coating an implantable stent as shown in FIGS. 14A-14C, include the steps of disposing a first coating composition on at least a portion of the abluminal surface of a stent strut and disposing a second coating composition on the first coating composition, wherein once disposed on at least a portion of the first coating composition, the second coating composition has an exposed abluminal surface and an exposed luminal surface or exposed side surface and wherein the second coating composition is prefabricated to conform to the stent. Preferably, the prefabricated second coating composition is prefabricated to conform to the stent. FIG. 14A shows a first coating composition 1100 disposed on at least a portion of the abluminal surface 1110 of a stent strut 1120. FIG. 14B shows a second coating composition 1130 that is prefabricated. FIG. 14C shows the prefabricated second coating composition 1130 disposed on the first coating composition 1100, wherein once disposed on at least a portion of the first coating composition 1100, the second coating composition 1130 has an exposed abluminal surface 1140, an exposed luminal surface 1150 and exposed side surfaces 1160.

Coating compositions can be disposed on the medical device by any of the techniques known in the art. Suitable method include, but are not limited to, dipping, spraying, painting, electroplating, evaporation, plasma-vapor deposition, cathodic-arc deposition, sputtering, ion implantation, electrostatically, electroplating, electrochemically, roll coating, selective droplet deposition, ionic droplet deposition, drop-on-demand processes or a combination of any of the above.

Removal of at least a portion of the coating composition so that the coating composition has an exposed abluminal surface and an exposed luminal surface or an exposed side surface can be done by any method known in the art. These methods include, but are not limited to, laser ablation, drilling, or chemical etching.

The secondary material or masking material can be any material so long as it can be removed such that the coating composition has an exposed abluminal surface and an exposed luminal surface. For example, the secondary material or masking material can be more electrochemically active than the coating composition, or the secondary material or masking material can be more soluble than the coating composition. Suitable secondary materials or masking materials include metals or polymers.

Techniques for removing secondary materials or masking materials include, but are not limited to, dissolution, dealloying or anodization processes. The secondary material or masking material can be removed from the coating composition by a dealloying process. In this method, the first coating composition and the secondary material or masking material are exposed to an acid which removes the secondary material or masking material. Thus, the coating composition is preferably one that will not dissolve when exposed to the acid, while the secondary metal or masking material is one that will dissolve.

Alternatively, the secondary material or masking material can be removed anodically. For example, silver may be removed anodically using a dilute nitric acid bath comprising up to 15% nitric acid, wherein the anode is the plated stent, and the cathode is platinum. Voltages up to 10V DC can be applied across the electrodes. The bath chemistry, temperature, applied voltage, and process time may be varied to vary the geometry, distribution, and depth of the coating layer. In another example, a Technic Envirostrip Ag 10-20 amps per square foot may be used with a stainless steel cathode.

In any of the above embodiments, the coating compositions can include a plurality of pores. Pores can be formed by any means known to one skilled in the art. Suitable methods of forming pores include micro-roughing techniques involving the use of reactive plasmas or ion bombardment electrolyte etching, sand blasting, laser etching and chemical etching. Pores can be disposed in a pattern such as near the exposed surfaces of the coatings or pores can be formed throughout the coatings described herein. Additionally, pores may occur naturally in the coating material, depending on the coating material used. For example, some types of carbon and polymers, suitable as coating compositions contain pores.

Additionally, in any of the above embodiments, any of the coating compositions can include at least one therapeutic agent. In certain embodiments, the therapeutic agent is disposed within the pores. To facilitate disposing a therapeutic agent in the pores, a solution or suspension of a the therapeutic agent can be formed by dissolving or suspending the therapeutic agent in an organic or aqueous solvent which is then used to dispose the therapeutic agent in the pores.

The medical devices and stents described herein may be used for any appropriate medical procedure. Delivery of the medical device can be accomplished using methods well known to those skilled in the art.

The description provided herein is not to be limited in scope by the specific embodiments described which are intended as single illustrations of individual aspects of certain embodiments. The methods, compositions and devices described herein can comprise any feature described herein either alone or in combination with any other feature(s) described herein. Indeed, various modifications, in addition to those shown and described herein, will become apparent to those skilled in the art from the foregoing description and accompanying drawings using no more than routine experimentation. Such modifications and equivalents are intended to fall within the scope of the appended claims.

All publications, patents and patent applications mentioned in this specification are herein incorporated by reference in their entirety into the specification to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. Citation or discussion of a reference herein shall not be construed as an admission that such is prior art.

Claims (29)

What is claimed is:

1. An implantable stent comprising:

(a) a stent sidewall structure having an abluminal surface and a luminal surface opposite the abluminal surface, the luminal surface being an outer surface of the stent sidewall structure and the abluminal surface being an inner surface of the stent sidewall structure, when the stent sidewall structure is delivered in a body lumen, the luminal surface to be at least partially exposed to face a lumen wall of the body lumen, and the adluminal surface to be at least partially exposed to face away from the lumen wall; and

wherein the coating has a cross-section in the shape of a “T”,

(b) a coating comprising a coating composition disposed over at least a portion of the abluminal surface of the stent sidewall structure,

wherein the coating has an exposed abluminal surface to face away from the abluminal surface of the stent sidewall structure and an exposed luminal surface to face the abluminal surface of the stent sidewall structure, and

wherein the coating composition comprises a therapeutic agent.

2. The stent of claim 1, wherein the coating composition is disposed directly on the abluminal surface of the stent.

3. The stent of claim 1, wherein the coating further comprises an adhesive material disposed between the abluminal surface of the stent and the coating composition.

7. The stent of claim 1, wherein the coating composition comprises a biostable polymer and the therapeutic agent comprises an anti-restenosis agent.

8. The stent of claim 1, wherein the coating further comprises

a first coating composition disposed over at least a portion of the abluminal surface, and

wherein the coating composition is a second coating composition disposed on the first coating composition.

9. The stent of claim 8, wherein the first coating composition is disposed directly on the abluminal surface and the second coating composition is disposed directly on the first coating composition.

10. The stent of claim 8, wherein the coating further comprises an adhesive material disposed between the abluminal surface of the stent and the first coating composition.

11. The stent of claim 10, wherein the stent further comprises an adhesive material disposed between the first coating composition and the second coating composition.

12. The stent of claim 8, wherein the first and second coating compositions are different.

13. The stent of claim 8, wherein the first coating composition and the second coating composition are the same.

14. The stent of claim 8, wherein the first coating composition comprises a first exposed surface area when disposed on the abluminal surface and the second coating composition comprises a second exposed surface area when disposed on the first coating composition, wherein the second exposed surface area is greater than the first exposed surface area.

15. The stent of claim 8, wherein the first coating composition or the second coating composition comprises a therapeutic agent.

Expandable implant for partial disc replacement and reinforcement of a disc partially removed in a discectomy and for reduction and maintenance of alignment of cancellous bone fractures and methods and apparatuses for same

Medical instrument with an asymmetrical microcrater in outer surface and a medicament holding fatty acid layer useful in administration of slow release drugs, e.g. in angioplasty, where medicament fatty acid layer can be mxied with acetone